Paperboard carton



oet. 21,1958

Filed Dec. 2. 1955 A. A. WILLIAMS PAPERBOARD CARTON.

A2' Sheets-Sheet 1 l oct. 21,1958

Filed no. a. 195s' A. A. WILLIAMS 2,857,088 PAPERBOARD CARTON 2 Sheets-.Sheet 2 PAPERBOARD CARTON Alford A. Williams, Charlotte, N. C., assignor, by direct and mesne assignments, of one-half to Stone Container Corporation, Chicago, Ill., a corporation of Illinois, and

one-half to Old Dominion Box Company, Inc., Char-k lotte, N. C., a corporation of North Carolina Application December 2, 1955, Serial No. 550,631

Claims. (Cl. 229-16) This invention relates generally to paperboard containers and more particularly is concerned with the construction of a paperboard container of the type which is adapted to be shipped or stored flat and is easily and speedily set up and locked by simple folding movements.

The principal objects of this invention are concerned with the provision of a novel container which is formed of a Single blank of paperboard, suitably cut and scored, which is extremely economical in that there is very little waste as a result of the formation of the blank; the pro-V vision of a container which is so constructed that it may be shipped or stored in at condition, and which is set up or assembled into a complete container, including a cover if desired, with very few movements requiring no skill to execute; the provision of a container which although easily set up as aforementioned, is nevertheless amazingly strong, having a double strength bottom wall and a double strength side or end wall; the provision of a container which although easily assembled and easily disassembled from set up to flattened condition, is nevertheless locked into set up condition when properly assembled without the use of adhesive or staples (other than used in the sub-assembly of the carton).

Other objects of the invention are the provision of a container which has novel means for forming a side or With the foregoing and other objects in view which will become more apparent to those skilled in the container art as the description proceeds, it will become manifest that the invention lies in the structure, arrangement ofA parts, and the relationship of the elements of the container to one another as Well as their adaptationto the performance of the functions giving rise to. the advantages of the invention. Variation in size and proportion of the carton and in the details thereof, as wellas the omission or inclusion of certain parts do not alect the basic concept of the invention, nor depart from the spirit thereof.

As required by the patent law, in order to lay a basis for the claims appended, a preferred embodiment of the invention is described in considerable detail for enabling a full and lucid understanding ofthe invention and how it is practiced and'used, but this explanation is only by' way of example and not limitation. There are also appended drawings illustrating this preferred embodiment, inv which: f

Fig. l is a top plan view of the blank for a paperboard container constructed in accordance Withthe invention, the blank having been cut from a sheet of paperboard or the like, and having none of its parts conjoined, as will be the case in other figures.

Fig. 2 is atop plan view of the carton or container' arranged at for storage or shipment, but with-two of thev container Walls permanently joined along common edges," iforming what has been termed herein the sub-assembly,Y

j 2,857,088 `APatented Oct. 21, 1958 2 and various parts folded to enable the flattening of the container. A

Fig. 3 is a fragmentary perspective view of the bottom of the container, illustrating the manner in which the subassembly of Fig. 2 is initially unfolded and arranged in assembling or setting vup the container.

Fig. 4 is a view similar to that of Fig. 3 but showing a further progression in 'steps of setting up the container,

the formerly folded parts involved having been fully opened and flattened outto enable the assemblyy to be made. l Y f i Fig. 5 is another perspective 'viev'v illustrating a step in the assembly or vsetting up` of the container, the same being shown in the process 4of forming the double endv wall to complete what may be considered thebasic portion of the container, consisting of bottom wall and side and end walls. p

Fig. 6 is a perspective View of the container in a further progressed step of setting upthe container, the double thickness end Wall'about to" be locked in place.

Fig. 7 is a perspective View showingl the completedl container with the cover being positioned over the basic portion of the container.

Fig. 8 is a median sectional view. taken through the assembled carton With. the'cover closed, along the line S--Sfof Fig. 7 and in the direction indicated.

Fig. 9 is a fragmentary sectional view taken through the double thickness end wall at the line 9 9 of Fig. 11

on an enlarged scale to show the manner in which the handle is assembled.

Fig. 10 is a fragmentary sectional view taken generally along the line 1010 of Fig. 9 and in the indicated direction to illustrate the means for assisting in locking the l carton in assembly and holding the adjacent support walls of the end of the carton in spaced relationship.

Fig. l1 is a Sectional view taken through the upper front corner of the closed containerv to rshow how the hinged cover is secured.

Depending upon the ultimate purposes of the container or carton, details may be varied. Cartons intended for use only once may beformed Without the details which may be appliedin the case 'of cartons to be used many times. Thus, rounded corners, die-cut thumb recesses,

cover aps, and the like are embellishments which are not needed for a carton which is likely to be used once and then discarded. As intimated above, the invention contemplates the use of the carton or container as an open-topped basket, to be covered by added members or even left open, if desired, so that the cover member and its receiving slit need not be provided.

The container or carton is especially intended for use in connection with small packages, such as can be carried for example by one hand, lbut of course it will be appreciated that the structure need not be so limited. Small appliances, poultry, toys, and the like are easily carried 1n the container, or packed and shipped therein. The containers may be sold or` distributed by retail establishments for customers requirements to carry groceries, hardware, and the like. In fact, the wide and almost unlimited use of the container renders the same a universal box or carton of great utility.

Referring now to the drawings, in Fig. 1 there is illustrated a singleV blank 20 which may be die cut from sheeting of paperboard, either corrugated or otherwise by any tangular and formed of two elongate portions, one portion Z1 of which is substantially wider in the particular embodiment and the other or. narrower portion 22 of which 3 is connected therewith at one end as will be described. It may be here mentioned that the wide portion 21 forms the side walls, one bottom wall thickness of the completed carton, and the cover, ifthere is to be one. The embodiment illustrated does have such a cover, and hence no further mention need be` made of the alternate construe tion.

The narrow portion 22 forms the end walls and one thickness of the bottom wall.

The two sections 21 and 22 are separated by a narrow elongate cut 24 almost along their entire length, but connected at 26 along a scored line which will facilitate bendlng. y

Considering first the section 21, the same has four main areas or rectangular parts designated in their connected order from left to right in Fig. l as 31, 32, 33 and 34. The rectangular part 31` will form the cover of the box or carton and it is hingedly secured to the section 32 along the scored line 35 and has a flap or tongue 36 hinged to its free edge along the score line 37. Suitable cutsl 38 at the formed corners enable a neat package to be formed upon assembly of the carton. Obviously these are a matter of design. The section or rectangular area 32 forms the rear side wall of the carton when assembled (as will be seen in Figs. 5 andy 6) and this part 32 is connected to the area 33 by lthe hinged score line 39. The center of the section 33 is scored along` its length for a purpose to be described in connectionv with folding and unfolding the blank 20, along the score line 41 and it is connected with the section 34 along. lthe hinged score line 42. The section 33 will form the inner bottom wall of the carton and the part 34 will form the front side wall of the carton.

At the ends of the parts or areas 32 and 34 opposite cut 24 there are provided two narrow anges 43 and 44V hingedly connected along 'the score lines 45, and 46 respectively to the parts 32 and 3.4. The length of the flanges 43 and 44 is substantially the same as the width of the sections or areas 3,2 and 34.v Each flange 43 and 44 has an integral lug or tooth at an end thereof spaced from the score lines 45 and 46. The lugs aredesignated 47 and 48 and it will be seen that they extend rightrand left oppositely away from oneanother. The purposes of flanges 43 and 44 will be described.

The end section or area34 has a flap 49 connected therewith along a hinged score line 51 which is slit at 52 in the center thereof and provided witha finger recess 53.

cut from the body ofthe section 3 4.,

The width of the sectionvZl, that' is tosa'yth`e length of each of the areas 31, 32, 33 and 34 den'es thelength of the completed and assembled carton. Obviously, the sections 21 and 22 can be of equal width or unequal width, depending upon the requirements ofthe user of the carton.

The width of the section 22 defines the width ofthe cornpleted and assembled carton, and this corresponds to the widths (the dimension considered transverse the elongate direction of the section 22,) of the areas or parts forming the same. There arel four areas or rectangular parts designated in their connected order from left to right in Fig. 1 as 61, 62, 63 and 64. The left hand area or part. 61 will form the inner wall of the double thickness end of the completed carton, and it isconnected to the area or part 62 along the hinged scoreline 65. The outer wall of the double thickness endwill be formed. by the area 62. Along the score line 65, and spaced equally inward from the opposite ends of the said score line 65, there are provided the perforations 66 and 67preferably rectangular and slightlyv larger than thecrossfsectionof. teeth 47 and 48. Obviously the areas 61- and 62 are to be folded facing oneanother, and the areas are providedvrespectively with a clear hand hole 68 and a partly cut ont hand hole 69 in position to be aligned when the parts are facing. The hand hole 69 has a flap 71 formed of the cut-out portion by reason of the hole being cut awayy from the part 6,2 I

section.

on only three sides of its perimeter. The technique for forming such a ap is well-known. When areas 61 and 62 are facing, the ap 71 is pushed through the opening 68 as a locking and assembly means, and to protect the hand against sharp paperboard edges.

The area or part 62 is connected to part or area 63 along the hinged score line 72, and in turn the area 63 is hingedly connected along the score line 73 with the section 64. The area 63 will form the outer bottom wall andthe area or part 64 will form the end wall of the carton or container opposite the double thickness end wall. The area 64 'has a flap 74 connected along score line 75 at its right hand edge (as viewed in Fig. l) which will form a trim or protective framing lip for the opening of the resultmg carton along its upper edge, as does the flap 4.9. Along the bottom of the area 64, there is a flange 76 hlngedly connected along the score line 77 which is used 1n connecting two partsy of the blank together as will be appreciated in connection with the explanation of other figures. The flange 76 is used where the connection, which 1s at a formed corner, is an overlapped stitched, stapled or glued connection. It may be dispensed with where the connection is made by the use of a butt joint which is taped. Both types of connections are common in the art.

In the explanation to follow, the various areas and parts will be referred to by their descriptive designations relative to the eventual formation of the carton. Thus, 31 will be called the cover member, 32 and 34 the rear and front sidewalls respectively, 33 and 63 the inner and outer bottom wallsrespectively, 61 and 62 the inner and outer end walls of the double thickness end of the carton, respectively, and 64 an end wall.

The section 22 is scoredV along its length as shown at 78 in the center thereof to facilitate folding of the entire If desired, the outer bottom wall 63 may be scored transverse thereof as indicated by the broken line 79 to render the attened carton or container more compact. The folded or flattened container as shown in Fig. 2 has the section 22 return bent upon itself and this results in an elongate formation which is easily folded approximately in half along the score line. 79- so that the right hand part of the elongate formation lies on top or bottom of the left hand part. This is indicated by the broken lines 22' to the left and bottom of Fig.. 2.

The blank 20 described above in considerable detail may be sold without the rst assembly step to be described. It will lie at and does not require complex apparatus or involved operations to be assembled, even without the tirst or connecting step. It is. preferred, however, to connect the parts in the manner taught by the invention to provide the sub-assembly of`Figure 2 which requires only bending and folding operations additionally to complete the setting up of the carton` The sub-assembly is accomplished by connecting the lower edge 77 of the end wall 64 with the edge 81 of the rear side wall 32. For example, the folding of the bottom half of sectionV 22 along its score line 78 upward as disposed in Fig. 1 and the folding of the section 21 along the score line 41, bringing the left half of the section as viewed in Fig. 1 upon the right half, will bring the edges 77 and 81 into coincidence. The flap 76 may be tucked under the side wall 32 and stitched or stapled in place with staples 82 or the resulting juncture may be taped.

The resulting sub-assembly is a hat formation as shown in Fig. 2, but with the parts of section 22 folded double. The conjoined edges are on the bottom of the formation shown in Fig. 2 but portions are broken away to show the construction.

The carton or container will hereinafter be designated generally to distinguish the same in its sub-assembled form from its blank form -designated 20. For example the carton 90 is flattened and disassembled in Fig. 2, and completely set up and assembled in Figs. 7 and 8. In its flattened condition, either with the elongate folded formation of section 22 return folded upon itself or otherwise, the carton 90 is ready for immediate setup or assembly. It is readily sub-assembled by the -manufacturer and stored or shipped in the folded condition of Fig. 2. The user may assemble and set up as the cartons are used, and needs no assembly 'apparatus or equipment, and no skilled labor to accomplish this. The assembly time is a matter of two or three seconds at most.

The progressive steps in assembling the carton 90, that is, in setting the same up from the sub-assembled condition are illustrated in Figs. 3, 4, and 6. Fig. 7 illustrates the last step in closing the cover of the carton 90.

The irst step is accomplished by separating the walls 32 and 34. This unfolds the wall 33 and the bottom wall 64, and flattens the remainder of the section 22. The act of separating the front and rear side walls is illustrated in Fig. 3, and the result is shown in Fig. 4. Note that the orientation of the carton 90 in this view is with the long dimensions of the front and rear side walls 32 and 34 vertical. When the walls 32 and 34 are sepa-` rated and the inner bottom wall 33 flattened, the anges 43 and 44 are bent inward to lie in substantially the same plane, the plane of the end wall. It will be appreciated that up to this point, the basic carton portion has front and rear side walls, a bottom wall, and one end wall, the opposite end wall being open and occupiedV only by the narrow hinged flanges 43 and 44. Considering the bottom 33, the teeth 47 and 48 are now directed toward the top of the carton 90 Ibeing formed.

Continuing with the setting up of the carton, the outer bottom wall 63 is folded along the line 72 into engagement with the inner bottom wall 33, rendering the bottom of the carton of double thickness and double strength. This is shown in Fig. 5, in which the orientation of the container or carton 90 has been changed to its normal disposition. In the same movement, the outer end wall 62 is brought over the open end of the basic container and laid upon the two llanges 43 and 44 while the inner end wall 61 is forced into the interior ofl the container, against and into engagement with the inner faces of the narrow anges 43 and 44. In this position it is coincident and aligned with the outer lside wall 62 so that the hand holes 68 and 69 are also aligned.

rlhis last described folding movement, brings the teeth or lugs 47 and 48 into registration with the perforations 66 and 67 respectively and the engagement thereof locks the carton in assembly. The dimensions of thewalls of the container 90 are chosen so that the inner end wall 61 fits snugly inside the basic carton. Separation of the front and rear walls 34 and 32 one from the other is prevented, of course by the locked engagement between teeth and perforations. v A

To complete the locking, the handle ilap 71 may be pushed through the hand hole 68 to the interio-r ofthe basic carton and folded up as shown in Figs. 8, 9, and l1. This helps nally adjust the alignment of end walls 61 and 62 with respect to one another and with respect to the anges 43 and 44. This is effective because the walls 61 and 62 are integral with the elongate strip including the outer bottom wall 63 wrapped around the bottom of the basic carton, up the end and folded inside to completely conne the flanges and prevent withdrawing of the teeth in vertical movement. A

In the event the basic carton, that is without the cover, is to be used', the inner end wall 61 may be secured in place permanently, to use the carton asa basket or opentopped box. Staples mayhsimply be driven through the double end wall or glue applied on the inside of the end wall 61. This however, is merely a possible use. The basic container may be kept in set up condition without fastening and disassembled whenever desired by simply goingbackward over the steps of setting up which have beenoutlined. The sub-assembly will have the same appearance generally as shown in Fig. 2, but without ,the

ccverl. Y l

Where the cover 31 is to be used, and this will likely be the majority of cases, after setting up the basic con-- tainer as described, and' placing the desired contents therein, the cover 31 is folded upon the top of the basic carton, and the flap 36 inserted into the slit 52 and the cover pressed closed. This also aids in locking the con-lv tainer since it prevents withdrawal of the inner side wall 61 which would release the teeth to permit separation of front and rear side walls 34 and 32.

As previously mentioned, the bottom of the resulting container 90 is of double thickness as is one end, andv considerable strength results therefrom.

The word rectangle as used herein includes any quadrilateral area having right angle corners.

It is felt that the advantages enumerated and many others will be apparent without the need for further discussion, but it is again desired to mention that considerable -variation is feasible without departing from the spirit or scope of the invention as defined by the appended claims.

What it is desired to secure by Letters Patent of the United States is:

l. A container formed of a single blank of paperboard and comprising, a lirst section having .a rear side wall,

irst bottom wall and front side wall integrally connected.

one with the other along a fold line between a common vertical edge of the front side wall and the third end wall and the opposite vertical edge of the third end wall being connected to an edge of the rear side wall to dispose said front and rear walls in `spaced alignment with' the third end wall connected therebetween, the remainder of the second section being disposed with the second bottom wall engaged against the first bottom wall on the exterior thereof `and the inner `and outer end walls folded against one another `and -disposed between the front and rear walls at the second vertical edges of said front and rear walls opposite the third end wall to close off and form a double end wall for the carton formed thereby, said second vertical edges having locking means connected therewith `and said inner and outer end panels having means at the line of fold interconnecting same for cooperably engaging with said locking means to prevent separation of the said side walls of the container.

2. A container formed of a single blank of paperboard and comprising, a lirst section having a rear side wall, first bottom wall and front side wall integrally connected along fold lines in the order named, a second section having an inner end wall, an outer end wall, a second bottom wall equal in size to the iirst bottom wall, and a third end wall integrally connectedv along fold lines in the or# der named, the two sections being integrally connected one with the other along a fold line between a common vertical edge of the front side wall and the third end walland the opposite vertical edge of the third end wall being connected to an edge of the rear side wall to dispose said front and rear walls in spaced alignment with the third end wall connected therebetween, the remainder ofthe second section being disposed with the second bottom wall engaged against the first bottom wall on the exterior thereof and the inner and outer end walls folded against one another and disposed between the front and -rear walls at the second vertical edges of said front and rear Walls opposite the third .end wall to Iclose olf and form a double end wall for the-carton formed thereby, said front and rear side walls having flanges integral therewith along the respective second verticaledges thereof and extending towardyone another Y-in -a plane parallel with the planes, `of the inner and outer end walls, vsaid anges being sandwiched between said inner and outer end'walls in locked engage-B169? t j .Y

3. A structure as described in claim 2 in which the 'rst' section has a cover member integral with said rear side wallj and hingedly connectedf therewith along 4a horizont'al edge parallel with and opposite to the fold line between the rear side wall and rst bottom wall, and the front side wall having means for enabling the cover to bek secured on top' of the carton to complete the enclosure thereof.

4. A structure as claimed in claim 3 in which the cover member has a ap and the fronty side wall has aslit for receiving the cover member flap-therein in locked engagement.

5. AV container formed of a single blanl of paperboard and comprising, a first section having a rear side wall, first bottom wall and front side wall integrally connected along fold lines inthe order named, a second section having an inner end wall, an outer end wall, a second bottom wall equal in size tothe rst bottom wall, and a third end wall integrally connected along fold lines in the order named, the two sections being integrally connected one with the other along a fold line between a common vertical edge of the front side wall and the third end wall vand the opposite vertical edge of the thirdend wall being connected'to an edge of the rear side wall to dispose said front and rear walls in spaced alignment with the third one another and disposedv between the front and rear walls at the second Vertical edges of said front and rear walls opposite the third end wall to close off and form a double end' wall for the carton formed thereby, said front and rear side walls having iianges integral therewith along the respective second vertical edges thereof .and extending toward one another in a plane parallel with the planes of the inner and outer end walls, said flanges being sandwiched between said inner and outer end walls in locked engagement, said flanges each having a lug, and there being aligned perforations for receiving said lugs to lock the flanges in place and prevent separation of the front .and rear side Walls.

6. A container formed of a single blank of paperboard and comprising, a first section having a rear side wall, first bottoni wall and front side wall integrally connected along fold lines in the order named, a second section having an' inner end wall, an outer end wall, a second bottom wall equalA in size to the first bottom. wall, and a third end wall integrally connected along fold lines in the order named, the two sections being integrally connected one with the other along a fold line between a vcommon vertical edge of the front side wall and the third end. wall andthe opposite vertical edge of the third end walll being connected to an edge of the` rear side wall to disposek said front and rear walls in spaced alignment with the third-end wall connected therebetween, the remainder of the second section being disposed with the second; bottom wall engaged against the irst bottom wall on the exterior thereof and the inner and outer end walls folded' against one another and' disposed between the front and rear walls at the second vertical edges of s'aid front and rear walls opposite the third end wall to close off and form a double end wall for the carton formed thereby, said front and rear side walls having flanges integral therewith along the respective second vertical edges thereof and extending toward one another in aplane parallel with the planesof the inner and outer end walls, Vsaid flanges being sandwiched between said inner andA outer endl walls in locked engagement, said flanges eachhaving a lug extending upward therefrom, and the fold line between said inner and outer end walls forming the topl edge of the' double end wall and having perforation's therein aligned with said-lugs and said lugs being disposed in said perforations to prevent lateral :noveend wallforming rectangle, an outer end wall formingv rectangle, a second bottom wall forming rectangle, and a third end` wall forming rectangle, the rectangles of the second section being integrally connected in the order named along parallel lines transverse of the second elongate rectangular formation, the two sections being iutegrally connected Valong a common edge between the front side wall forming rectangle and the third end wall forming rectangle, said common edge being at a right angle to all of said fold lines and disposing the sections tit) side by side, the second section being return folded'upon itself along the length of the section and the first section being folded upon itself but along a fold line substantially in the center of said first bottom wall forming rectangle parallel with the first mentioned fold lines of the said first section, and the edge of said third end wall lforming rectangle opposite the common edge being thereby arranged in coincidence with an edge of said front wall forming rectangle, said side wall forming rectangles having iianges formed on edges thereof disposed opposite the edge of the said first section which is joined to the sec ond sect-ion, said flanges and inner and outer end wall forming rectangles having means provided thereon to enable locking the said container in assembly when set up.

8. A structure as described in claim 7 in which said last mentioned means comprise lugs on said anges and perforations in said inner and outer end wall forming rectangles adapted to receive said lugs.

9. A container formed of Aa single blank of paperboard and comprising, a first section having a rear side wall, iirst bottom wall and front side wall integrally connected along fold lines in the order named, a second section having an inner end wall, an outer end wall, .a second bottom wall equal -in size to the first bottom wall, and a third end wall integrally connected along fold lines in the order named, the two sections being integrally connected one with the other along a fold line between a common vertical edge of the front side wall andthe third end wall and the opposite vertical edge of thethird end wall being connected to an edge of the rear side wall to dispose said front and rear walls in spaced alignment with the third end wall connected therebetween, the remainder of the second section being disposed with the second bottom wall engaged against the rst bottom wall on the exterior thereof and the inner and outer end walls folded against one another and disposed between the front and rear walls at the second vertical edges of said front and rear walls opposite the third end wall to close off and form a double end wall for the carton formed thereby, said front and rear side walls having flanges integral therewith along the respective second vertical edges thereof and extending toward one another in a plane parallel with the planes of the inner and outer end walls, said flanges being sandwiched between said inner and outer end walls in locked engagement, said flanges each having a lug, and there being aligned perforations for receiving said lugs to lock the anges in place and prevent separation of the front and rear side walls, and aligned hand holes in said inner and outer end walls including a iiap in one hand hole engaged in the other hand hole .and holding the inner and outer end walls in engaged alignment with said iianges locked and sandwiched between.

10. A structure as claimed in claim 9 in which the flanges are spaced aparta distance greater than the horizontal length of said ap.

References Cited in the le of this patent UNITED STATES PATENTS 184,126 Arthur Nov. 7, 1876 815,704 Hirsch Mar. 20, 1906 882,688 -Janicke Mar. 24, 1908 gli a, 

